基于数字孪生的采煤机摇臂壳体制造过程建模与误差溯源

    Modeling and Error Traceability of the Shearer′s Rocker Arm Shell Manufacturing Process Based on Digital Twin Technology

    • 摘要: 采煤机是煤矿智能化建设的核心设备之一。其制造过程遵循典型的单件、小批量模式,导致可用于过程控制的数据样本极其有限。在零部件质量控制方面,当前主要依赖机加工后的最终检验,缺乏有效的过程预警和实时干预措施。此外,人、机、料、法、环境等多源因素造成的复杂且难以控制的变异性,进一步加剧了采煤机零部件机加工过程中的质量管控挑战。本文提出基于数字孪生的多阶段制造过程控制方法,其核心是构建一个深度融入物理机理,并能随生产数据动态演化的数字孪生体,通过对制造过程的多维映射与仿真分析,实现对质量波动的实时诊断与源头追溯。该方法以双驱动机制为核心,融合了物理知识驱动的工艺知识模型与数据驱动的图注意力网络模型。在此框架下,通过识别关键误差传播路径,图网络自适应量化节点影响,进而提出加权质量影响关键性指数。该方法通过整合多维动态特征,构建可解释系统以识别关键工艺节点。通过采煤机摇臂壳体零件制造案例研究,验证了该方法的有效性:制造过程网络关系经物理约束约简后减少19.4%,基于图注意力网络(GAT)的动态权重模型在验证集上的准确率与F1分数均达到85%以上,针对加权误差传播关键性指数(WEPCI)识别出关键节点,通过广度优先搜索(BFS)算法实现了39条误差路径的智能排序与溯源。

       

      Abstract: Shearer is one of the core pieces of equipment in intelligent coal mine construction. Its manufacturing process follows a typical single-piece, small-batch production model, resulting in extremely limited data samples available for process control. In terms of component quality control, current practices primarily rely on final inspections after machining, lacking effective process early warning and real-time intervention measures. Furthermore, the complex and difficult-to-control variability caused by multiple factors, including personnel, machinery, materials, methods, and environment, further exacerbates the quality control challenges during the machining process of shearer components. This paper proposes a multistage manufacturing process control method based on digital twin. Its core lies in constructing a digital twin deeply integrated with physical mechanisms that dynamically evolves with production data. Through multidimensional mapping and simulation analysis of the manufacturing process, it enables real-time diagnosis and root-cause tracing of quality fluctuations. This method centers on a dual-drive mechanism, integrating a process knowledge model driven by physical knowledge with a data-driven graph attention network model. Within this framework, the graph network identifies critical error propagation paths and adaptively quantifies node influences, thereby proposing a weighted quality impact criticality index. By integrating multidimensional dynamic features, the method constructs an interpretable system to identify key process nodes. Its effectiveness is validated through a case study of the shearer′s rocker arm shell component. The network relationships in the manufacturing process were reduced by 19.4% after physical constraint reduction. The dynamic weight model based on Graph Attention Network (GAT) achieved an accuracy rate and F1 score of over 85% on the validation set. Key nodes were identified based on the Weighted Error Propagation Critical Index (WEPCI), and the intelligent sorting and traceability of 39 error paths were realized through the Breadth-first Search (BFS) algorithm.

       

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